TECHNICAL FIELD
BACKGROUND ART
[0002] Conventionally, as a polishing apparatus of a substrate, there has been known a polishing
apparatus that includes a substrate holding member that holds the substrate and a
polishing table that holds a polishing pad and polishes the substrate while pressing
the substrate against the polishing pad (for example, see PTLs 1, 2, and 3). Conventionally,
as such a polishing apparatus, there has been known a polishing apparatus that allows
optically measuring a polishing state of a substrate (for example, see PTLs 1 and
2). Specifically, the polishing apparatus includes a sensor head that includes a projector
that projects incident light, a condenser that condenses incident light projected
from the projector and projects it to a substrate, and an optical receiver that receives
reflected light reflected by the substrate. The polishing apparatus measures a polishing
state of the substrate based on a parameter related to a light amount of the reflected
light received by the optical receiver (referred to as a light amount parameter).
CITATION LIST
PATENT LITERATURE
SUMMARY OF INVENTION
TECHNICAL PROBLEM
[0004] When the polishing pad abrades in association with use of the polishing apparatus
in the conventional polishing apparatus as described above, a distance between the
condenser and the substrate becomes possibly closer than a reference distance set
in advance. When the distance between the condenser and the substrate thus becomes
smaller than the reference distance, "defocus" in which a focal point of the incident
light condensed by the condenser does not match a position originally set possibly
occurs. When the defocus occurs, accurately measuring the polishing state of the substrate
possibly becomes difficult.
[0005] The present invention has been made in view of the above-described things, and one
object is to provide a technique that allows accurately measuring a polishing state
of a substrate.
SOLUTION TO PROBLEM
(Aspect 1)
[0006] To achieve the above-described object, a polishing apparatus according to one aspect
of the present invention includes a substrate holding member and a polishing table.
The substrate holding member is configured to hold a substrate. The polishing table
is configured to hold a polishing pad. The polishing apparatus is configured to polish
the substrate while pressing the substrate against the polishing pad. The polishing
apparatus includes a sensor head, a displacement mechanism, an abrade amount measurement
device, and a control device. The sensor head includes a projector, a condenser, and
an optical receiver. The projector is configured to project incident light. The condenser
is configured to condense the incident light projected from the projector and cause
the incident light to be incident on the substrate. The optical receiver is configured
to receive reflected light reflected by the substrate. The displacement mechanism
is configured to relatively displace the condenser with respect to the substrate to
change a distance between the condenser and the substrate. The abrade amount measurement
device is configured to measure an abrade amount of the polishing pad. The control
device is configured to measure a polishing state of the substrate based on a light
amount parameter. The light amount parameter is a parameter related to a light amount
of the reflected light received by the optical receiver. The control device is configured
to control the displacement mechanism based on the abrade amount of the polishing
pad measured by the abrade amount measurement device such that the distance between
the condenser and the substrate is maintained at a preliminarily set reference distance.
[0007] According to the aspect, even when the polishing pad abrades, the distance between
the condenser and the substrate can be maintained at the reference distance, and therefore
defocus can be suppressed. This allows accurately measuring the polishing state of
the substrate.
(Aspect 2)
[0008] In the above-described aspect 1, the control device may be configured to measure
a polishing ending point of the substrate as the polishing state of the substrate.
According to the aspect, the polishing ending point of the substrate can be accurately
measured.
(Aspect 3)
[0009] In the above-described aspect 1 or aspect 2, the control device may be configured
to further calculate a distance between the condenser and the substrate such that
the light amount parameter becomes larger than a predetermined value by performing
machine learning based on a data group associating the light amount parameter with
the distance between the condenser and the substrate, and use the calculated distance
as the reference distance. According to the aspect, the distance between the condenser
and the substrate can be the distance such that the light amount parameter becomes
larger than the predetermined value without manpower.
(Aspect 4)
[0010] In one aspect of any of the above-described aspects 1 to 3, the control device may
be configured to further predict a change in light amount parameter as a change in
the light amount parameter in association with a lapse of a polishing time corresponding
the process condition by performing machine learning based on a data group associating
a process condition as a condition related to a polishing rate of the substrate by
the polishing apparatus with the light amount parameter. The control device may be
configured to calculate an abnormal range of the change in light amount parameter
equivalent to a case where abnormality occurs in the polishing apparatus based on
the predicted change in light amount parameter and cause a storage medium to store
the calculated abnormal range of the change in light amount parameter.
(Aspect 5)
[0011] In the above-described aspect 4, the control device may be configured to further
determine whether abnormality occurs in the polishing apparatus based on the abnormal
range of the change in light amount parameter stored in the storage medium and an
actually measured value of the change in light amount parameter during polishing the
substrate by the polishing apparatus. According to the aspect, whether abnormality
occurs in the polishing apparatus can be determined.
(Aspect 6)
[0012] In any one aspect among the above-described aspects 1 to 5, the control device may
be configured to further determine whether substrate slip-out in which the substrate
comes off from the substrate holding member occurs based on whether the light amount
parameter is smaller than a threshold. According to the aspect, whether the substrate
slip-out occurs can be determined.
(Aspect 7)
[0013] In one aspect of any of the above-described aspects 1 to 6, the sensor head may be
disposed on the polishing table. The sensor head may be configured to rotate together
with the polishing table during polishing the substrate by the polishing apparatus.
The control device may be configured such that when a relative position between the
substrate and the sensor head is at a position where the incident light is incident
on the surface to be polished during polishing the substrate by the polishing apparatus,
the control device may further control projection timing of the projector such that
the projector projects the incident light. According to the aspect, a useless energy
consumption, such as while incident light being not incident on the substrate, incident
light being projected, can be suppressed.
(Aspect 8)
[0014] In the above-described aspect 7, a light transmitting member configured to transmit
the incident light condensed by the condenser and the reflected light reflected by
the substrate may be disposed on a part of the polishing pad. According to the aspect,
even when optical transmission performance of the polishing pad is low, the polishing
state of the substrate can be optically measured.
(Aspect 9)
[0015] To achieve the above-described object, a polishing method according to one aspect
of the present invention includes: a step of condensing incident light projected from
a projector during polishing a substrate by a polishing apparatus by a condenser to
cause the incident light to be incident on the substrate, receiving reflected light
reflected by the substrate by an optical receiver, and measuring a polishing state
of the substrate based on a light amount parameter as a parameter related to a light
amount of the reflected light received by the optical receiver; and a step of relatively
displacing the condenser with respect to the substrate based on an abrade amount of
the polishing pad against which the substrate is pressed such that a distance between
the condenser and the substrate is maintained at a preliminarily set reference distance
during polishing the substrate by the polishing apparatus.
[0016] According to the aspect, even when the polishing pad abrades, the distance between
the condenser and the substrate can be maintained at the reference distance, and therefore
defocus can be suppressed. This allows accurately measuring the polishing state of
the substrate.
BRIEF DESCRIPTION OF DRAWINGS
[0017]
Fig. 1A is a configuration diagram schematically illustrating a main configuration
of a polishing apparatus according to Embodiment 1.
Fig. 1B is a schematic plan view of a polishing machine main body according to Embodiment
1.
Fig. 2 is a cross-sectional view schematically illustrating an enlarged peripheral
configuration of a substrate holding member of the polishing apparatus according to
Embodiment 1.
Fig. 3 is a schematic diagram for describing configurations of a sensor head and a
light source/spectral module according to Embodiment 1.
Fig. 4 is a schematic diagram for describing a configuration of a displacement mechanism
according to Embodiment 1.
Fig. 5 is a flowchart depicting exemplary control of a sensor and the displacement
mechanism by a control device according to Embodiment 1.
Fig. 6 is one example of a flowchart of reference distance setting control according
to Embodiment 2.
Fig. 7 is one example of a flowchart of abnormality determination control according
to Embodiment 3.
Fig. 8A is a schematic diagram for describing a control process according to Step
S31 of Embodiment 3.
Fig. 8B is a schematic diagram for describing a control process according to Step
S31 of Embodiment 3.
Fig. 9 is one example of a flowchart of substrate slip-out control according to Embodiment
4.
DESCRIPTION OF EMBODIMENTS
[0018] The following will describe respective embodiments of the present invention with
reference to the drawings. Note that in the following respective Embodiments, the
same reference numerals are given to identical or corresponding configurations and
the description is appropriately omitted in some cases. Additionally, the drawings
of the application are schematically illustrated for ease of understanding of the
features of the embodiments, and dimensional proportions of respective components
and the like are not always same as those of the actual ones.
(Embodiment 1)
[0019] Fig. 1A is a configuration diagram schematically illustrating a main configuration
of a polishing apparatus 100 according to Embodiment 1 of the present invention. The
polishing apparatus 100 according to this embodiment is a polishing apparatus that
allows chemical mechanical polishing (Chemical Mechanical Polishing: CMP). Specifically,
the polishing apparatus 100 illustrated in Fig. 1A as an example mainly includes a
polishing machine main body 10, a sensor 30, a displacement mechanism 60, an abrade
amount measurement device 70, and a control device 80. Note that in Fig. 1A, the front
view of the polishing machine main body 10 is schematically illustrated. Additionally,
the configuration of a part of the polishing machine main body 10 is schematically
illustrated in the cross-sectional view.
[0020] Fig. 1B is a schematic plan view (top view) of the polishing machine main body 10.
Note that a polishing table 11 described later of the polishing machine main body
10 in Fig. 1B is illustrated in a state of being rotated by a predetermined angle
with respect to the polishing table 11 in Fig. 1A. Therefore, Fig. 1B is drawn such
that a light transmitting member 92 described later can be visually perceived from
the upper side. With reference to Fig. 1A and Fig. 1B, the polishing machine main
body 10 mainly includes the polishing table 11, a substrate holding member 12, and
a dresser 13.
[0021] The polishing table 11 is configured to hold and rotate a polishing pad 90. Specifically,
the polishing table 11 according to this embodiment is configured by a disk-shaped
member, and the polishing pad 90 is bonded to the upper surface. The upper surface
(front surface) of the polishing pad 90 is equivalent to a polishing surface 91. Additionally,
the polishing table 11 is connected to a table rotation shaft 14. Rotatably driving
the table rotation shaft 14 by a driving mechanism (such as a rotation motor) rotates
the polishing table 11. During polishing, a surface to be polished Wfc described later
of a substrate Wf is pressed against the polishing surface 91. The control device
80 described later controls the rotation operation of the polishing table 11. "R1"
illustrated in Fig. 1B is an example of the rotation direction of the polishing table
11.
[0022] The specific type of the polishing pad 90 is not particularly limited, and various
polishing pads, such as a hard foam type polishing pad, a non-woven fabric type polishing
pad, or a suede type polishing pad, can be used. The polishing pad 90 is appropriately
set according to the type of the substrate Wf.
[0023] The substrate holding member 12 is a member for holding the substrate Wf. The substrate
holding member 12 is configured to rotate the surface to be polished Wfc of the substrate
Wf while pressing the surface to be polished Wfc against the polishing pad 90. Specifically,
the substrate holding member 12 is connected to a substrate rotation shaft 15. Rotatably
driving the substrate rotation shaft 15 by a driving mechanism (such as the rotation
motor) rotates the substrate holding member 12. Note that "R2" illustrated in Fig.
1B is an example of the rotation direction of the substrate holding member 12. To
the upper end of the substrate rotation shaft 15, a pressing cylinder (not illustrated)
for pressing the substrate rotation shaft 15 downward is connected. When the substrate
rotation shaft 15 is pressed downward by the pressing cylinder, the substrate Wf held
onto the substrate holding member 12 is pressed to the polishing pad 90.
[0024] Fig. 2 is a cross-sectional view schematically illustrating an enlarged peripheral
configuration of the substrate holding member 12 of the polishing apparatus 100, and
specifically schematically illustrates the enlarged configuration in the vicinity
of A1 in Fig. 1A in the cross-sectional view. As illustrated in Fig. 2, the substrate
Wf according to this embodiment includes a substrate core Wfa and a film Wfb formed
on the surface of the substrate core Wfa. The surface (lower surface) of the film
Wfb is equivalent to the surface to be polished Wfc. Although the material of the
substrate core Wfa is not specifically limited, a glass-based material is used as
an example in this embodiment. The material of the film Wfb is not specifically limited,
and an inorganic compound, an organic compound, or the like can be used. In this embodiment,
a wiring pattern structure is included inside the film Wfb. That is, an example of
the substrate Wf according to this embodiment is a printed-circuit board.
[0025] With reference to Fig. 1A and Fig. 1B again, the substrate holding member 12 according
to this embodiment is configured to swing with respect to the polishing pad 90. Specifically,
the substrate rotation shaft 15 of the substrate holding member 12 is connected to
a substrate swing shaft 17 via a substrate swing arm 16. Swingably driving the substrate
swing shaft 17 by the driving mechanism swings the substrate swing arm 16 so as to
draw an arc around the substrate swing shaft 17 (that is, turns clockwise and counterclockwise),
and as a result, the substrate holding member 12 similarly swings. Note that the substrate
holding member 12 is a member generally also known as a "top ring," a "polishing head,"
and the like. The control device 80 controls the rotation operation and the swing
operation of the substrate holding member 12. Note that "SW1" illustrated in Fig.
1B is one example of the swinging direction of the substrate holding member 12.
[0026] The dresser 13 is a member for dressing the polishing surface 91 of the polishing
pad 90. An abrasive grain (such as a diamond) is disposed on the lower surface of
the dresser 13. The dresser 13 is connected to a dresser rotation shaft 18. Rotatably
driving the dresser rotation shaft 18 by the driving mechanism (such as the rotation
motor) rotates the dresser 13. Additionally, to the upper end of the dresser rotation
shaft 18, a pressing cylinder (not illustrated) for pressing the dresser rotation
shaft 18 downward is connected. By the dresser rotation shaft 18 being pressed downward
by the pressing cylinder, the dresser 13 is pressed to the polishing pad 90. Note
that "R3" illustrated in Fig. 1B is one example of the rotation direction of the dresser
13.
[0027] Additionally, the dresser 13 according to this embodiment is configured to swing
with respect to the polishing pad 90. Specifically, the dresser rotation shaft 18
of the dresser 13 is connected to a dresser swing shaft 20 via a dresser swing arm
19. Swingably driving the dresser swing shaft 20 by a driving mechanism (such as a
swing motor) swings the dresser swing arm 19 around the dresser swing shaft 20, and
as a result, the dresser 13 similarly swings. The control device 80 controls the rotation
operation and the swing operation of the dresser 13. Note that "SW2" illustrated in
Fig. 1B is one example of the swinging direction of the dresser 13.
[0028] During dressing by the dresser 13, pure water is supplied to the polishing surface
91 of the polishing pad 90 and the polishing table 11 rotates. In the state, by the
dresser 13 rotating while swinging, the polishing surface 91 is dressed. Thus performing
dressing allows dressing the polishing surface 91 of the polishing pad 90 and recovering
the polishing rate of the substrate Wf by the polishing apparatus 100.
[0029] The polishing apparatus 100 includes a slurry supply mechanism (not illustrated)
for supplying the polishing surface 91 of the polishing pad 90 with slurry (polishing
slurry). As the slurry, for example, a solution containing an abrasive grain, such
as silicon oxide, aluminum oxide, and cerium oxide, can be used. The specific kind
of the slurry only needs to be appropriately set according to the kind of the film
Wfb. Note that the slurry may be supplied from the upper side of the polishing pad
90, may be supplied from the lower side, or may be supplied from both the upper side
and the lower side. In the polishing apparatus 100, each of the polishing table 11
and the substrate holding member 12 rotates in the presence of the slurry to polish
the surface to be polished Wfc (the film Wfb) of the substrate Wf.
[0030] The control device 80 integrally controls the operation of the polishing apparatus
100. Specifically, the control device 80 according to this embodiment includes a computer.
The computer (specifically, a microcomputer) includes a Central Processing Unit (CPU)
81 as a processor, a storage 82 as a non-transitory storage medium, and the like.
The computer is electrically connected to a controlled unit of the polishing apparatus
100. The CPU 81 as the processor of the control device 80 operates based on a command
of a program stored in the storage 82 to control the operation of the polishing machine
main body 10. Additionally, the control device 80 according to this embodiment also
controls the operation of the sensor 30 and the displacement mechanism 60 described
later. The control device 80 that controls the sensor 30, the displacement mechanism
60, and the abrade amount measurement device 70 has a function as a "polishing state
measurement system."
[0031] Note that in this embodiment, while one control device 80 has a function as the control
device of the polishing machine main body 10, the sensor 30, and the displacement
mechanism 60, the configuration is not limited to this. For example, the polishing
apparatus 100 may individually include a control device for the polishing machine
main body 10, a control device for the sensor 30, and a control device for the displacement
mechanism 60 (that is, the plurality of control devices may control the controlled
units).
[0032] Subsequently, the sensor 30 will be described. With reference to Fig. 1A, the sensor
30 includes a sensor head 40 and a light source/spectral module 50. The sensor head
40 and the light source/spectral module 50 according to this embodiment are disposed
on the polishing table 11 as one example. The sensor head 40 and the light source/spectral
module 50 rotate together with the polishing table 11 during polishing the substrate
Wf by the polishing apparatus 100.
[0033] As illustrated in Fig. 2 and Fig. 1B, on a part of the polishing pad 90 according
to this embodiment, the light transmitting member 92 through which incident light
L1 and reflected light L2 described later are passable is disposed. In this embodiment,
the light transmitting member 92 is configured by a material having light transparency,
specifically a window member (namely, a translucent window member) made of a transparent
material, such as transparent plastic and a transparent glass. The incident light
L1 condensed by a condenser 42 described later passes through the light transmitting
member 92 and then is incident on the substrate Wf (specifically, the surface to be
polished Wfc). Additionally, the reflected light L2 reflected by the substrate Wf
passes through the light transmitting member 92 and then is received by an optical
receiver 43 described later.
[0034] As in this embodiment, by disposing the light transmitting member 92 on a part of
the polishing pad 90, even when the optical transmission performance of the polishing
pad 90 is low, the polishing state of the substrate Wf can be optically measured.
[0035] As illustrated in Fig. 2, the sensor head 40 according to this embodiment is connected
to the polishing table 11 via a tubular tool 31. The tool 31 is connected to the polishing
table 11 such that the incident light L1 and the reflected light L2 described later
can pass inside the tool 31. Specifically, the tool 31 according to this embodiment
is fitted to a tubular hole disposed in the polishing table 11 as one example. Additionally,
the top end surface of the tool 31 according to this embodiment is connected to a
lower surface of a glass plate 32 disposed on the lower surface of the light transmitting
member 92. The glass plate 32 effectively suppresses entrance of a foreign matter,
such as slurry, into the inside the tool 31 (inside the tube). Note that the tool
31 is preferably in close contact with the lower surface of the glass plate 32 so
as not to form a gap between the tool 31 and the glass plate 32.
[0036] Fig. 3 is a schematic diagram for describing the configurations of the sensor head
40 and the light source/spectral module 50. Note that Fig. 3 omits the illustration
of the displacement mechanism 60 described later. The sensor head 40 includes a projector
41, the condenser 42, and the optical receiver 43. The light source/spectral module
50 includes a light source 51 and a spectroscope 52.
[0037] The type of the light source 51 is not specifically limited and, for example, a laser
light emitter and a halogen lamp can be used. The laser light emitter is used as one
example of the light source 51 in this embodiment. The control device 80 controls
the operation of the light source 51.
[0038] The sensor head 40 internally houses the projector 41, the condenser 42, and the
optical receiver 43. The projector 41 is a device that projects the incident light
L1 to a predetermined direction. Specifically, the projector 41 according to this
embodiment projects the incident light L1 toward the direction of the substrate Wf.
Additionally, the projector 41 according to this embodiment is configured by an optical
fiber. The optical fiber has one end (the end portion on the opposite side of the
substrate Wf side) connected to the light source 51. The light emitted from the light
source 51 passes through the optical fiber and is projected as the incident light
L1.
[0039] The condenser 42 is a device that condenses the incident light L1 projected from
the projector 41 and causes it to be incident on the substrate Wf (specifically, the
surface to be polished Wfc). As long as the function is provided, the specific configuration
of the condenser 42 is not specifically limited, and a lens (namely, a condenser lens)
is used as one example of the condenser 42 in this embodiment. The lens as the condenser
42 is disposed between the projector 41 and the substrate Wf. Note that although Fig.
3 omits the illustrations of the above-described glass plate 32 and light transmitting
member 92, actually, the incident light L1 condensed by the condenser 42 passes through
the glass plate 32 and the light transmitting member 92 and then is incident on the
substrate Wf.
[0040] Additionally, in this embodiment, a distance (D) between the condenser 42 and the
substrate Wf is set to a predetermined "reference distance." Note that in this embodiment,
the distance (D) between the condenser 42 and the substrate Wf specifically means
"the distance between a principal point (P) of the lens as the condenser 42 and the
surface to be polished Wfc of the substrate Wf." However, the configuration is not
limited to this, and, for example, the distance (D) between the condenser 42 and the
substrate Wf may be a distance between another predetermined position in the condenser
42 and another predetermined position in the substrate Wf.
[0041] Additionally, in this embodiment, the "reference distance" is set to a value same
as a focal point distance of the condenser 42. Thus, in this embodiment, the focal
point of the incident light L1 condensed by the condenser 42 matches the surface to
be polished Wfc of the substrate Wf.
[0042] The optical receiver 43 is a device that receives the reflected light L2 reflected
by the substrate Wf. Specifically, the optical receiver 43 according to this embodiment
is configured by an optical fiber. The optical fiber has one end (the end portion
on the opposite side of the substrate Wf side) connected to the spectroscope 52.
[0043] The spectroscope 52 is a device that disperses the reflected light L2 and converts
a light amount parameter of the dispersed light (a parameter related to the light
amount) into a digital signal. In this embodiment, the light amount or reflectance
is used as one example of the light amount parameter. The digital signal converted
by the spectroscope 52 is transmitted to the control device 80.
[0044] The control device 80 controls the light source 51 to control projection timing of
the incident light L1 from the projector 41. Specifically, when the relative position
between the substrate Wf and the sensor head 40 is at a position where the incident
light L1 is incident on the substrate Wf during polishing by the polishing apparatus
100, the control device 80 according to this embodiment projects the incident light
L1 from the projector 41. The details are as follows.
[0045] First, the sensor head 40 rotates together with the polishing table 11 and further
the substrate holding member 12 also swings. In view of this, when the projector 41
projects the incident light L1 at timing of the sensor head 40 passing through below
the substrate Wf held onto the substrate holding member 12, the incident light L1
can be reliably incident on the substrate Wf.
[0046] Therefore, in this embodiment, a range of a rotation phase (rad) of the polishing
table 11 and a range of a swing phase (rad) of the substrate holding member 12 (they
are referred to as "target phase ranges") at which the sensor head 40 passes through
below the substrate Wf (that is, the incident light L1 is incident on the substrate
Wf) are preliminarily obtained, and they are stored in the storage 82 of the control
device 80 in advance. Then, the control device 80 obtains the rotation phase of the
polishing table 11 based on a detection result of a sensor (not illustrated) that
detects the rotation phase of the polishing table 11, obtains the swing phase of the
substrate holding member 12 based on a detection result of a sensor (not illustrated)
that detects the swing phase of the substrate holding member 12, and when these obtained
rotation phase and swing phase are within the preliminarily set target phase ranges,
the light source 51 is caused to emit light to project the incident light L1 from
the projector 41. Thus, the control device 80 causes the incident light L1 to be reliably
incident on the surface to be polished Wfc of the substrate Wf during polishing by
the polishing apparatus 100.
[0047] According to the above-described configuration, a useless energy consumption, such
as while incident light L1 being not incident on the substrate, incident light L1
being projected, can be suppressed.
[0048] The control device 80 measures the polishing state of the substrate Wf based on the
reflected light L2 received by the optical receiver 43. Specifically, the control
device 80 according to this embodiment measures the polishing state of the substrate
Wf based on the light amount parameter related to the light amount of the reflected
light L2 (the light amount or the reflectance as one example in this embodiment).
Additionally, the control device 80 according to this embodiment measures data regarding
a film thickness of the substrate Wf during polishing as one example of the polishing
state of the substrate Wf. More specifically, the "polishing ending point" of the
substrate Wf during polishing is measured. Note that as the measurement mechanism
itself that measures the polishing ending point based on the reflected light L2, for
example, the publicly-known techniques as in, for example, PTL 1 and PTL 2 are applicable,
and the specific contents are not specifically limited. However, the control device
80 according to this embodiment, for example, measures the polishing ending point
by the following measurement mechanism.
[0049] The control device 80 according to this embodiment indexes the light amount parameter
of the reflected light L2 based on the data transmitted from the spectroscope 52,
subsequently performs a noise removal process of a time waveform of the indexed data,
and analyzes the waveform after the noise removal process is performed to detect the
light amount parameter and feature points (feature points, such as a local maximal
value and a local minimal value and a threshold of a differential value). The value
that has been detected (detected value) has a correlation relationship with the film
thickness. Therefore, the control device 80 calculates the film thickness of the substrate
Wf based on the detected value and obtains it, and when the film thickness of the
substrate Wf becomes a reference film thickness set in advance, it is determined that
the film thickness of the substrate Wf reaches the polishing ending point. Thus, the
control device 80 measures the polishing ending point of the substrate Wf. When the
control device 80 determines that the film thickness of the substrate Wf reaches the
polishing ending point, the control device 80 causes the polishing apparatus 100 to
end the polishing.
[0050] Subsequently, the displacement mechanism 60, the abrade amount measurement device
70, and control of the displacement mechanism 60 by the control device 80 will be
described. Fig. 4 is a schematic diagram for describing the configuration of the displacement
mechanism 60. The displacement mechanism 60 is a mechanism configured to relatively
displace the condenser 42 with respect to the substrate Wf upon receiving the command
from the control device 80 to change the distance (D) between the condenser 42 and
the substrate Wf. Specifically, the displacement mechanism 60 according to this embodiment
displaces the condenser 42 in a vertical direction upon receiving the command from
the control device 80 to displace the condenser 42 in the direction of approaching
the surface to be polished Wfc of the substrate Wf or the direction of separating
from the surface to be polished Wfc.
[0051] As long as the function is provided, the specific configuration of the displacement
mechanism 60 is not specifically limited, and the publicly-known technique that allows
a target member to be vertically displaced is applicable. In this embodiment, a linear
motion actuator 61 is used as the specific example of the displacement mechanism 60.
The configuration of the linear motion actuator 61 is not specifically limited. In
this embodiment, as one example of the linear motion actuator 61, the one that includes
a rail 62 that vertically extends and a slider 63 that slides along the rail 62 is
used. The slider 63 is connected to a condenser holding member 44 that holds the condenser
42. The slider 63 is vertically displaced to vertically displace the condenser 42.
[0052] Note that the configuration of the displacement mechanism 60 is not limited to the
one illustrated in Fig. 4 as an example. For example, as the displacement mechanism
60, the other publicly-known mechanisms, such as a piston-cylinder linear motion actuator
and a ball screw linear motion actuator, can be used.
[0053] Additionally, the displacement mechanism 60 may displace not only the condenser 42
among the sensor head 40, but also displace the projector 41 and the optical receiver
43 together with the condenser 42. Specifically, in this case, the displacement mechanism
60 only needs to displace the sensor head 40 itself, for example.
[0054] With reference to Fig. 1A, the abrade amount measurement device 70 is a device that
measures an abrade amount (µm) of the polishing pad 90. Specifically, the abrade amount
measurement device 70 according to this embodiment includes a displacement sensor
71. The displacement sensor 71 according to this embodiment measures the displacement
in the vertical direction of the dresser rotation shaft 18 of the dresser 13 to measure
the displacement in the vertical direction of the dresser 13 and measure the abrade
amount of the polishing pad 90 based on the measurement result. The detection result
of the displacement sensor 71 is transmitted to the control device 80. Note that the
abrade amount measurement device 70 according to this embodiment at least measures
the abrade amount of the polishing pad 90 during polishing the substrate Wf by the
polishing apparatus 100 upon receiving the command of the control device 80. As the
abrade amount measurement device 70, the publicly-known technique as described in
PTL 3 described above is applicable, and therefore the abrade amount measurement device
70 will not be described in detail any further.
[0055] Fig. 5 is a flowchart depicting exemplary control of the sensor 30 and the displacement
mechanism 60 by the control device 80 according to this embodiment. The control device
80 measures the polishing state of the substrate Wf based on the light amount parameter
of the reflected light L2 received by the optical receiver 43 during polishing the
substrate Wf by the polishing apparatus 100 (Step S10: this will be referred to as
"polishing state measurement control"). Furthermore, the control device 80 controls
the displacement mechanism 60 based on the abrade amount of the polishing pad 90 measured
by the abrade amount measurement device 70 such that the distance (D) between the
condenser 42 and the substrate Wf is maintained at the preliminarily set reference
distance during polishing the substrate Wf by the polishing apparatus 100 (Step S11:
this will be referred to as "displacement control"). Note that Step S10 and Step S11
may be simultaneously performed during polishing the substrate Wf. Alternatively,
while the same substrate Wf is in the polishing process, Step S10 and Step S11 may
be separately (non-simultaneously) performed.
[0056] In the displacement control according to Step S11, specifically, the control device
80 controls the displacement mechanism 60 such that the condenser 42 is separated
from the substrate Wf by the abrade amount of the polishing pad 90 to maintain the
distance between the condenser 42 and the substrate Wf at the reference distance.
As described above, in this embodiment, the reference distance is set to the value
same as the focal point distance of the condenser 42. The displacement control will
be specifically described with a value example as follows.
[0057] First, for example, assume that in a state before polishing of the substrate Wf by
the polishing apparatus 100 starts, the new polishing pad 90 is held onto the polishing
table 11. The distance (D) between the condenser 42 and the substrate Wf in the polishing
pad 90 held onto the polishing table 11 is set to the reference distance. Assume that
the polishing pad 90 abrades, for example, 10 µm in association with the use of the
polishing apparatus 100. Specifically, assume that the polishing pad 90 abrades by
10 µm in association with the progress of polishing the substrate Wf during polishing
the substrate Wf by the polishing apparatus 100. In this case, the control device
80 obtains that the abrade amount of the polishing pad 90 is 10 µm based on the detection
result of the displacement sensor 71.
[0058] Here, provisionally, when the polishing apparatus 100 does not include the displacement
mechanism 60, as described above, in the case where the polishing pad 90 abrades by
10 µm, the distance between the substrate Wf and the condenser 42 becomes shorter
than the original reference distance by 10 µm. In this case, the above-described "defocus"
possibly occurs.
[0059] In contrast to this, according to this embodiment, the control device 80 controls
the displacement mechanism 60 during polishing the substrate Wf by the polishing apparatus
100 to displace the condenser 42 to the lower side by 10 µm, thus separating the condenser
42 from the substrate Wf by 10 µm. This allows maintaining the distance between the
substrate Wf and the condenser 42 at the reference distance originally set (namely,
the focal point distance).
[0060] As described above, according to the polishing apparatus 100 according to this embodiment,
even when the polishing pad 90 abrades, the distance between the condenser 42 and
the substrate Wf can be maintained at the reference distance, thus ensuring suppressing
defocus. This allows accurately measuring the polishing state of the substrate Wf.
Specifically, according to this embodiment, the polishing ending point of the substrate
Wf can be accurately measured.
(Polishing Method)
[0061] Note that the polishing method according to this embodiment is achieved by the above-described
polishing apparatus 100. Specifically, the polishing method according to this embodiment
includes a step of measuring the polishing state of the substrate Wf based on the
light amount parameter of the reflected light L2 received by the optical receiver
43 during polishing the substrate Wf by the polishing apparatus 100 (referred to as
a "polishing state measuring step") and a step of controlling the displacement mechanism
60 based on the abrade amount of the polishing pad 90 measured by the abrade amount
measurement device 70 such that the distance between the condenser 42 and the substrate
Wf during polishing the substrate Wf by the polishing apparatus 100 is maintained
at the preliminarily set reference distance D (referred to as a "displacement step").
[0062] The polishing state measuring step is equivalent to Step S10 and the displacement
step is equivalent to Step S11 in Fig. 5. Since the details of the polishing method
according to this embodiment overlaps with the above-described description of the
polishing apparatus 100, the description will be omitted.
[0063] The polishing method according to this embodiment described above also allows suppressing
defocus and accurately measuring the polishing state of the substrate Wf.
(Embodiment 2)
[0064] Subsequently, Embodiment 2 of the present invention will be described. The polishing
apparatus 100 according to this embodiment differs from Embodiment 1 described above
in that the control device 80 further performs reference distance setting control
described below.
[0065] Specifically, the control device 80 according to this embodiment performs machine
learning based on a data group associating the light amount parameter of the reflected
light L2 received by the optical receiver 43 with the distance between the condenser
42 and the substrate Wf in the reference distance setting control to calculate the
distance between the condenser 42 and the substrate Wf such that the light amount
parameter of the reflected light L2 becomes larger than the predetermined value, and
uses the calculated distance as "the reference distance between the condenser 42 and
the substrate Wf." The reference distance setting control will be described below
with reference to the flowchart.
[0066] Fig. 6 is one example of the flowchart of the reference distance setting control
performed by the control device 80 according to this embodiment. In Step S20, the
control device 80 obtains the data group associating the light amount parameter of
the reflected light L2 received by the optical receiver 43 with the distance (D) between
the condenser 42 and the substrate Wf. The light amount parameter is a physical parameter
related to the light amount of the reflected light L2 and the light amount or the
reflectance is used as one example in this embodiment.
[0067] Each time that the polishing apparatus 100 performs polishing, the control device
80 causes the storage 82 of the control device 80 to store the above-described light
amount parameter and distance (D). This allows increasing the data amount of the data
group as the number of uses of the polishing apparatus 100 increases.
[0068] Next, the control device 80 performs machine learning based on the data group obtained
in Step S20 to calculate the distance between the condenser 42 and the substrate Wf
such that the light amount parameter of the reflected light L2 received by the optical
receiver 43 becomes larger than the predetermined value and uses the calculated distance
as the reference distance (Step S21). Note that Step S21 is performed before the polishing
apparatus 100 starts polishing the substrate Wf.
[0069] Specifically, in Step S21, the control device 80 performs machine learning based
on the data group obtained in Step S20 to calculate the correlation relationship between
the light amount parameter and the distance between the condenser 42 and the substrate
Wf (namely, a regression formula). The control device 80 calculates "the distance
between the condenser 42 and the substrate Wf such that the light amount parameter
becomes larger than the predetermined value" using the calculated correlation relationship.
Then, the control device 80 uses the calculated distance as the reference distance.
[0070] As the "predetermined value" of "the distance between the condenser 42 and the substrate
Wf such that the light amount parameter becomes larger than the predetermined value"
described above, for example, the use of a value 90% or more of the maximum value
of the light amount parameter is preferred, the use of a value 95% or more of the
maximum value of the light amount parameter is more preferred, and the use of a value
98% or more of the maximum value of the light amount parameter is further preferred.
In this embodiment, as the "predetermined value," the maximum value of the light amount
parameter (namely, 100% of the maximum value) is used. Note that the maximum value
of the light amount parameter specifically means the light amount parameter having
the largest value in the data group obtained in Step S20.
[0071] That is, in Step S21, the control device 80 according to this embodiment calculates
"the distance between the condenser 42 and the substrate Wf in the data group obtained
in Step S20 such that the light amount parameter becomes the maximum" and uses the
calculated distance as the reference distance. Note that it is considered that when
the distance between the condenser 42 and the substrate Wf matches the focal point
distance of the condenser 42, the light amount parameter becomes the maximum.
[0072] After Step S21 described above, the control device 80 performs Step S22. Step S22
is also performed before the polishing apparatus 100 starts polishing the substrate
Wf. In Step S22, the control device 80 controls the displacement mechanism 60 such
that the distance between the condenser 42 and the substrate Wf becomes the reference
distance calculated in Step S21.
[0073] Thus, according to this embodiment, the distance between the condenser 42 and the
substrate Wf can be set such that the light amount parameter of the reflected light
L2 becomes larger than the predetermined value without manpower. Specifically, according
to this embodiment, the distance between the condenser 42 and the substrate Wf can
be a distance such that the light amount parameter of the reflected light L2 becomes
the maximum without manpower.
(Embodiment 3)
[0074] Subsequently, Embodiment 3 of the present invention will be described. The polishing
apparatus 100 according to this embodiment differs from Embodiment 1 and Embodiment
2 described above in that the control device 80 further performs abnormality determination
control described below.
[0075] Fig. 7 is one example of a flowchart of the abnormality determination control performed
by the control device 80 according to this embodiment. In Step S30, the control device
80 obtains the data group associating a "process condition" as a condition related
to a polishing speed of the substrate Wf by the polishing apparatus 100 (polishing
rate) with the light amount parameter of the reflected light L2 received by the optical
receiver 43.
[0076] Although the process condition is not specifically limited as long as it is a condition
related to the polishing rate, for example, a condition including at least one of
the type of the substrate Wf, a polishing load (N) as a load for pressing the substrate
Wf against the polishing pad 90, a rotation speed (rpm) of the polishing table 11,
a rotation speed (rpm) of the substrate holding member 12, the type of the slurry
supplied to the polishing pad 90, polishing time (sec) of the substrate Wf, and the
type of the polishing pad 90 can be used. As one example, the process condition according
to this embodiment includes all of the matters.
[0077] Note that as the type of the substrate Wf, for example, information, such as the
material of the surface to be polished Wfc of the substrate Wf and the shape of the
surface to be polished Wfc of the substrate Wf can be used. As the type of the slurry,
for example, information, such as the material of the slurry and the concentration
of the slurry, can be used. As the type of the polishing pad 90, for example, information,
such as the material of the polishing surface 91 of the polishing pad 90 and the surface
roughness of the polishing surface 91, can be used.
[0078] Additionally, each time the polishing apparatus 100 performs polishing, the control
device 80 causes the storage 82 of the control device 80 to store the above-described
process condition and light amount parameter. Thus, as the number of uses of the polishing
apparatus 100 increases, the data amount of the data group can be increased.
[0079] Subsequent to Step S30, the control device 80 performs Step S31. In Step S31, the
control device 80 performs machine learning based on the data group obtained in Step
S30 to predict "the change in light amount parameter" as the change in the light amount
parameter of the reflected light L2 in association with a lapse of the polishing time
corresponding to the process condition. Then, the control device 80 calculates the
range of the change in light amount parameter equivalent to a case where abnormality
occurs in the polishing apparatus 100 based on the predicted change in light amount
parameter (namely, an abnormal range of the change in light amount parameter) and
causes the storage 82 (storage medium) to store the calculated abnormal range of the
change in light amount parameter. Note that Step S31 is performed before the polishing
apparatus 100 starts polishing the substrate Wf.
[0080] Here, when the process condition (the condition related to the polishing rate) differs,
as a result of difference in decrease speed of the thickness of the substrate Wf (film
thickness) in association with a lapse of the polishing time, the change in light
amount parameter also has a different aspect. Accordingly, a correlation relationship
is recognized between the process condition and the change in light amount parameter.
Based on the knowledge, the control device 80 according to this embodiment predicts
the change in light amount parameter through machine learning based on the data group
associating the process condition with the light amount parameter as in Step S31 described
above. Additionally, in this embodiment, "abnormality occurs in the polishing apparatus
100" specifically means that the polishing rate of the substrate Wf by the polishing
apparatus 100 is outside the normal speed range.
[0081] The following will describe the control process according to Step S31 described above
with reference to the drawings. Fig. 8A and Fig. 8B are schematic diagrams for describing
the control process according to Step S31. Specifically, Fig. 8A schematically illustrates
the state of the change in light amount parameter when the process condition is a
predetermined condition (referred to as a "condition A"). Meanwhile, Fig. 8B schematically
illustrates the state of the change in light amount parameter when the process condition
is a "condition B" different from the condition A. Note that Fig. 8A and Fig. 8B plot
the light amount parameter (the light amount or the reflectance as one example in
this embodiment) in the vertical axis and the polishing time in the horizontal axis.
[0082] A line 200a in Fig. 8A is a line schematically illustrating the change in light amount
parameter predicted in Step S31 when the process condition is the condition A. A range
partitioned by a line 201a and a line 202a (a range equal to or more than the light
amount parameter of the line 201a and equal to or less than the light amount parameter
of the line 202a) is a range of the change in light amount parameter equivalent to
the case where the polishing apparatus 100 is normal ("the normal range of the change
in light amount parameter"). Then, the range where the light amount parameter is smaller
than the line 201a and the range where the light amount parameter is larger than the
line 202a are the range of the change in light amount parameter equivalent to the
case where abnormality occurs in the polishing apparatus 100 ("the abnormal range
of the change in light amount parameter").
[0083] The control device 80 subtracts the predetermined value from the change in light
amount parameter of the line 200a to obtain the change in light amount parameter of
the line 201a, and adds the predetermined value to the change in light amount parameter
of the line 200a to obtain the change in light amount parameter of the line 202a.
Then, the control device 80 calculates the range where the change in light amount
parameter is smaller than the line 201a and the range where the change in light amount
parameter is larger than the line 202a as "the abnormal range of the change in light
amount parameter corresponding the condition A" and causes the storage 82 to store
it.
[0084] A line 200b in Fig. 8B is a line schematically illustrating the change in light amount
parameter predicted in Step S31 when the process condition is the condition B. The
range partitioned by a line 201b and a line 202b (the range equal to or more than
the light amount parameter of the line 201b and the range equal to or less than the
light amount parameter of the line 202b) is the change in light amount parameter equivalent
to the case where the polishing apparatus 100 is normal ("the normal range of the
change in light amount parameter"). Then, the range where the light amount parameter
is smaller than the line 201b and the range where the light amount parameter is larger
than the line 202b is the range of the change in light amount parameter equivalent
to the case where abnormality occurs in the polishing apparatus 100 ("the abnormal
range of the change in light amount parameter").
[0085] The control device 80 subtracts the predetermined value from the change in light
amount parameter of the line 200b to obtain the change in light amount parameter of
the line 201b, and adds the predetermined value to the change in light amount parameter
of the line 200b to obtain the change in light amount parameter of the line 202b.
The control device 80 calculates the range where the change in light amount parameter
is smaller than the line 201b and the range where the change in light amount parameter
is larger than the line 202b as "the abnormal range of the change in light amount
parameter corresponding to the condition B" as and causes the storage 82 to store
it.
[0086] Step S31 in Fig. 7 is performed as described above. After Step S31, the control device
80 performs Step S32. Step S32 is performed during polishing the substrate Wf by the
polishing apparatus 100. In Step S32, the control device 80 determines whether abnormality
occurs in the polishing apparatus 100 based on the abnormal range of the change in
light amount parameter stored in Step S31 and the actually measured value of the change
in light amount parameter measured using the sensor 30 (the actually measured value
of the change in light amount parameter measured based on the reflected light L2 received
by the optical receiver 43). Specifically, the control device 80 determines whether
the actually measured value of the change in light amount parameter measured during
polishing is within the abnormal range of the change in light amount parameter stored
in the storage 82 to determine whether abnormality occurs in the polishing apparatus
100.
[0087] For example, when the process condition of polishing by the polishing apparatus 100
is the condition A, in Step S32, when the actually measured value of the change in
light amount parameter is within the abnormal range of Fig. 8A, the control device
80 determines that some sort of abnormality occurs in the polishing apparatus 100.
Meanwhile, when the actually measured value of the change in light amount parameter
is outside the abnormal range of Fig. 8A, (within the normal range), the control device
80 determines that abnormality does not occur (normal) in the polishing apparatus
100.
[0088] For example, when the process condition of polishing by the polishing apparatus 100
is the condition B, in a case where the actually measured value of the change in light
amount parameter is within the abnormal range of Fig. 8B, the control device 80 determines
that some sort of abnormality occurs in the polishing apparatus 100, and in a case
where the actually measured value is outside the abnormal range of Fig. 8B (within
the normal range), the control device 80 determines that abnormality does not occur
(normal) in the polishing apparatus 100.
[0089] According to this embodiment described above, whether abnormality occurs in the polishing
apparatus 100 can be determined.
[0090] Note that the control device 80 causes the storage 82 of the control device 80 to
store the determination result of abnormality determination. Additionally, the polishing
apparatus 100 may include a notification device (not illustrated) that notifies a
user of the polishing apparatus 100 of predetermined information. In this case, the
control device 80 may notify the notification device of the determination result of
abnormality determination. As the notification device, a lamp, a buzzer, a display,
a combination of them, and the like can be used.
(Embodiment 4)
[0091] Subsequently, Embodiment 4 of the present invention will be described. The polishing
apparatus 100 according to this embodiment differs from Embodiment 1, Embodiment 2,
and Embodiment 3 described above in that substrate slip-out determination control
described below is further performed.
[0092] Specifically, in the substrate slip-out determination control, the control device
80 according to this embodiment determines whether the "substrate slip-out" in which
the substrate Wf comes off from the substrate holding member 12 occurs based on whether
the light amount parameter of the reflected light L2 received by the optical receiver
43 is smaller than a preliminarily set threshold.
[0093] When the substrate Wf is held onto the substrate holding member 12, the light amount
parameter of the reflected light L2 has a value at least equal to or more than the
threshold. However, when substrate slip-out occurs, the light amount parameter of
the reflected light L2 becomes smaller than the threshold. Using the property, the
control device 80 determines presence/absence of substrate slip-out through comparison
between the light amount parameter of the reflected light L2 and the threshold. The
substrate slip-out control will be described below with reference to the flowchart.
[0094] Fig. 9 is one example of the flowchart of the substrate slip-out control performed
by the control device 80 according to this embodiment. The control device 80 performs
the flowchart of Fig. 9 during polishing the substrate Wf by the polishing apparatus
100. In Step S40, the control device 80 determines whether the light amount parameter
of the reflected light L2 received by the optical receiver 43 (the actually measured
value of the light amount parameter) is smaller than the preliminarily set threshold.
It is only necessary to obtain an appropriate value of the threshold by experiment,
simulation, or the like in advance and store it in the storage 82 of the control device
80.
[0095] When Step S40 is determined to be YES (that is, when the light amount parameter of
the reflected light L2 is smaller than the threshold), the control device 80 determines
that substrate slip-out occurs (Step S41). On the other hand, when Step S40 is determined
to be NO, the control device 80 determines that substrate slip-out does not occur
(Step S42).
[0096] According to this embodiment described above, whether substrate slip-out occurs can
be determined.
[0097] Note that the control device 80 causes the storage 82 of the control device 80 to
store the determination result of substrate slip-out. Additionally, when the polishing
apparatus 100 includes the above-described notification device, the control device
80 may notify the notification device of the determination result of substrate slip-out.
[0098] Although the embodiments of the present invention have been described in detail above,
the present invention is not limited to the specific embodiments. Various changes
and modifications can be made without departing from the scope of the gist of the
present invention as defined in the appended claims.
REFERENCE SIGNS LIST
[0099]
- 11
- polishing table
- 12
- substrate holding member
- 40
- sensor head
- 41
- projector
- 42
- condenser
- 43
- optical receiver
- 60
- displacement mechanism
- 70
- abrade amount measurement device
- 80
- control device
- 82
- storage (storage medium)
- 90
- polishing pad
- 91
- polishing surface
- 92
- light transmitting member
- 100
- polishing apparatus
- L1
- incident light
- L2
- reflected light
- Wf
- substrate